Visual Inspection Systems for Containers of Liquid Pharmaceutical Products

Abstract

An automated visual inspection (AVI) system may include at least one profile view imager having an optical axis that passes through an inspection object, a proximal polarizing film axially aligned with the optical axis, a liquid crystal device axially aligned with the optical axis, a distal polarizing film axially aligned with the optical axis, and at least one light source oriented to emit illumination toward the distal polarizing film. Alternatively, or additionally, an AVI system may include a profile view imager having an optical axis that enters a container through a side wall of the container, and a ring light that is coaxially aligned with a central axis of the container, below the container, and oriented to emit light toward a bottom of the container. The AVI system may also include a bottom imager coaxially aligned with the central axis and oriented to view the bottom of the container.

1 . An automated visual inspection system, comprising:
 a profile view imager having an optical axis that passes through an inspection object that is at least partially translucent, the inspection object being positioned at a first distance from the profile view imager;   a proximal polarizing film axially aligned with the optical axis, positioned at a second distance from the profile view imager, and oriented perpendicular to the optical axis, the second distance being less than the first distance;   a liquid crystal device axially aligned with the optical axis, positioned at a third distance from the profile view imager, and oriented parallel to the proximal polarizing film, the third distance being greater than the second distance and less than the first distance;   a distal polarizing film axially aligned with the optical axis, positioned at a fourth distance from the profile view imager, and oriented parallel to the proximal polarizing film and the liquid crystal device, the fourth distance being greater than the first distance; and   a light source oriented to emit illumination toward the distal polarizing film.   
     
     
         2 . The system as in  claim 1 , wherein the inspection object is a container selected from a group including: a vial, a syringe, or a cartridge. 
     
     
         3 . (canceled) 
     
     
         4 . The system as in  claim 1 , further comprising:
 (a) a ring light that is coaxially aligned with a central axis of the inspection object, below the inspection object, and oriented to emit light toward a bottom of the inspection object, (b) a bottom imager coaxially aligned with a central axis of the inspection object and oriented to view the bottom of the inspection object, (c) a container rotation mechanism, or (d) one or more additional profile view imagers oriented parallel with a respective optical axis to view at least a portion of a respective profile of the inspection object.   
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . The system as in  claim 4 , comprising the one or more additional profile view imagers, wherein the one or more additional profile view imagers consist of four profile view imagers. 
     
     
         8 . A method for imaging an inspection object that is at least partially translucent, the method comprising:
 emitting illumination from a light source;   polarizing the illumination emitted from the light source using a distal polarizing film;   passing the polarized illumination through at least a portion the inspection object, then through a liquid crystal device, and then through a proximal polarizing film; and   capturing one or more images of the inspection object with a profile view imager, the profile view imager having an optical axis that intersects a side wall of the inspection object.   
     
     
         9 . The method of  claim 8 , wherein the inspection object is a container selected from a group including: a vial, a syringe, or a cartridge. 
     
     
         10 . (canceled) 
     
     
         11 . The method of  claim 8 , further comprising:
 analyzing, by one or more processors, the one or more images of the inspection object to detect at least one defect associated with the inspection object and/or contents of the inspection object.   
     
     
         12 . The method of  claim 11 , wherein the at least one defect includes a particle or fiber within the container. 
     
     
         13 . An automated visual inspection system, comprising:
 a profile view imager having an optical axis that enters a container through a side wall of the container, the container being at least partially translucent;   a ring light that is coaxially aligned with a central axis of the container, below the container, and oriented to emit light toward a bottom of the container; and   a holding means for supporting and/or securing the container.   
     
     
         14 . The system as in  claim 13 , further comprising:
 at least one of: (a) a container rotator, (b) one or more additional profile view imagers oriented parallel with a respective optical axis to view at least a portion of a respective profile of the container, or (c) a bottom imager coaxially aligned with the central axis and oriented to view the bottom of the container.   
     
     
         15 . The system as in  claim 14 , comprising the (b) one or more additional profile view imagers, wherein the one or more additional profile view imagers consist of four profile view imagers. 
     
     
         16 . (canceled) 
     
     
         17 . The system as in  claim 13 , further comprising:
 a proximal polarizing film axially aligned with the optical axis, positioned at a second distance from the profile view imager, and oriented perpendicular to the optical axis, the second distance being less than a first distance between the container and the profile view imager;   a liquid crystal device axially aligned with the optical axis, positioned at a third distance from the profile view imager, and oriented parallel to the proximal polarizing film, the third distance being greater than the second distance and less than the first distance;   a distal polarizing film axially aligned with the optical axis, positioned at a fourth distance from the profile view imager, and oriented parallel to the proximal polarizing film and the liquid crystal device, the fourth distance being greater than the first distance; and   a light source oriented to emit illumination toward the distal polarizing film.   
     
     
         18 . The system as in  claim 13 , further comprising:
 a container rotator.   
     
     
         19 . A method for imaging a container that is at least partially translucent and holds a liquid sample, the method comprising:
 illuminating the container with a ring light, the ring light being coaxially aligned with a central axis of the container, below the container, and oriented to emit light toward a bottom of the container;   capturing one or more profile view images with a profile view imager, the profile view imager having an optical axis that enters the container through a side wall of the container: and   capturing one or more bottom images with a bottom imager coaxially aligned with the central axis and oriented to view the bottom of the container.   
     
     
         20 . The method of  claim 19 , further comprising:
 analyzing, by one or more processors, the (a) one or more profile view images of the container or (b) the one or more bottom images of the container, to detect at least one defect associated with the container and/or contents of the container.   
     
     
         21 . The method of  claim 20 , wherein the at least one defect includes: (a) a particle or fiber within the container, or (b) a bruised container seal. 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . The method of  claim 19 , further comprising:
 analyzing, by one or more processors, (a) one or more profile view images of the container or (b) the one or more bottom images of the container, to classify at least one defect associated with the container and/or contents of the container.   
     
     
         26 . The method of  claim 25 , comprising analyzing, by one or more processors, the (a) one or more profile view images of the container, wherein the at least one defect associated with the container and/or contents of the container is classified as one of:
 a particle within the container, a fiber within the container, or a bruised container seal.   
     
     
         27 . (canceled) 
     
     
         28 . The method of  claim 25 , comprising analyzing, by one or more processors, the (b) the one or more bottom images of the container, wherein the at least one defect associated with the container and/or contents of the container is classified as a particle within the container or a fiber within the container. 
     
     
         29 . The method of  claim 19 , further comprising:
 analyzing, by one or more processors, (a) the one or more profile view images of the container, or (b) the one or more bottom images of the container, to classify the container as either acceptable or a reject.   
     
     
         30 . (canceled) 
     
     
         31 . (canceled)